Mesh Ball Impregnated with Soap

ABSTRACT

The invention relates to a method and apparatus for a cleaning product comprising a foam portion containing at least one additive, said foam portion attached to a mesh sponge portion as well as a method of making the same. The instant invention is for use as a lightweight, hygienic cleaning product capable of controlling release of additives such as cleaning agents and additives for skin care or aesthetic or therapeutic purposes.

BACKGROUND OF INVENTION

1. Field of the Invention

The present invention relates to a cleaning product, and moreparticularly to a bath sponge comprising a foam portion containingadditives for controlled release, attached to a mesh sponge portion forcontact with the surface to be cleaned.

2. Description of the Related Art

The use of bath ruffles or mesh sponges demonstrates certain advantagesover the traditional use of bath clothes, natural sponges, or syntheticfoam sponges. First, mesh sponges are usually larger and lighter,leading to ease of manipulation and safety to the feet if dropped,kicked, or stepped on in the shower or bath tub. Second, due to thecharacteristics of the material from which they are made, mesh spongesare usually easier to clean and dry than bath clothes or traditionalsponges, and therefore more hygienic. Third, they present a softer andmore effective cleaning and exfoliating surface to the skin. Meshsponges also suffer from some of the same disadvantages as traditionalcleaning materials in that typically soap or cleansing agents must beconstantly reapplied to the sponge for application to the skin duringuse, leading to the simultaneous manipulation under wet and slipperyconditions of both a large mesh sponge and a relatively heavy and hardbar of soap or container of cleanser. This manipulation can lead todropping the bar of soap or container of cleanser resulting in injury tothe feet or toes of the bather and the presence of a slippery object onthe floor of the tub or shower resulting in a slip hazard.

Several attempts have been made to solve some of the limitationsassociated with traditional bath cloths. U.S. Pat. Nos. 6,187,728 and7,320,953 appear to utilize the casting of a hard soap either into oraround a sponge or non-woven cloth material. U.S. Pat. Nos. 2,156,940and 4,457,640 appear to show the shaping of the cleaning material into apouch into which can be inserted a bar of soap or a volume of liquidcleanser. Addition of a pocket into a sponge to contain a bar of soap orcasting of soap inside the center of a mesh sponge would result in aheavy and unwieldy object, negating the lightness and ease ofmanipulation benefits of the mesh sponge.

What is desired, therefore, is a cleaning product that is lightweight,easy to manipulate, safe if dropped during bathing, easy to clean, andhygienic, and that would not require constant reapplication of cleansingagents or other components desirable for skin care or aesthetic ortherapeutic purposes with the resulting hazards and difficulties suchmanipulation presents.

SUMMARY OF THE INVENTION

It is therefore an object of this invention to provide a cleaningproduct having a foam portion containing one or more additives, attachedto a mesh sponge portion. In some embodiments, the foam portion isgenerally enclosed by the mesh sponge portion. In other embodiments,portions of the foam portion surface as well as portions of the meshsponge portion surface is exposed.

In some embodiments, the foam portion is selected from the groupconsisting of a hydrophilic foam, hydrogel, hydrophobic foam,polyurethane, polyethylene, polyvinyl alcohol, polyvinylpyrrolidone,cellulose, and polyethylene oxide, and combinations thereof. In someembodiments, the foam portion is the reaction product of a prepolymermixture containing the desired additives whereby the additives aregenerally dispersed uniformly throughout the foam product. In otherembodiments, the additives are added to the foam portion after formationof the foam product. In some embodiments, one or more additives arepresent in the prepolymer mixture during the production of the foamproduct, while others are added to the foam product after production.

In some embodiments, the foam portion contains at least onesuperabsorbent polymer.

In some embodiments, the additives are one or more compounds selectedfrom the group consisting of soaps, detergents, waxes, polishes, drugs,cosmetics, biologicals, volatiles, odor absorbing and controllingcompositions, perfumes, oils, essential oils, vitamins, bactericides,microbicides, skin conditioning agents, moisturizers, plant extracts,and combinations thereof.

In some embodiments, the outer mesh sponge is comprised of at least onelayer of netting arranged in the form of a bath ruffle. In someembodiments, the outer mesh sponge is comprised of netting of at leasttwo different materials or textures to provide a sponge having more thanone quality of cleaning surface.

In some embodiments, some parts of the netting intended to be formedinto the mesh sponge portion are in contact with or immersed in theprepolymer mixture used to form the foam portion, such that part of thenetting comprising the mesh sponge portion would be incorporated intothe structure of the foam portion. In other embodiments, attachment isprovided to attach the foam portion to the mesh sponge portion. In otherembodiments, the mesh sponge portion generally encloses the foam portionsuch that additional attachment is not required. In still otherembodiments, the mesh sponge portion only partially encloses the foamportion, leaving some portion of the surface of the foam portionexposed, but enclose enough of the foam portion that it is retainedwithout further attachment.

Another object is to provide a method of manufacturing a cleaningproduct of the current invention. In some embodiments, the methodcomprises providing a preformed foam portion containing one or moreadditives, and attaching said foam portion to a mesh sponge portion. Insome embodiments, the mesh sponge portion is preformed and attached to apreformed foam portion. In other embodiments, the mesh sponge portion isformed around a preformed foam portion. In still other embodiments, thefoam portion is provided as a prepolymer mixture, and allowed topolymerize in such a fashion that the resulting foam productincorporates segments of the mesh sponge portion.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the invention believed to be novel and the elementscharacteristic of the invention are set forth with particularity in theclaims. The figures are for illustration purposes only. The inventionitself, however, both as to organization and method of operation, may beunderstood by reference to the detailed description which follows takenin conjunction with the accompanying drawings in which the drawings showtypical embodiments of the invention and are not intended to be limitedof its scope.

FIG. 1 shows an external view of certain embodiments of the cleaningproduct in accordance with the invention.

FIG. 2 shows a section view of one embodiment of the cleaning product inaccordance with the invention shown in FIG. 1.

FIG. 3 shows a section view of a second embodiment of the cleaningproduct in accordance with the invention shown in FIG. 1.

FIG. 4 shows a cutaway view of a third embodiment of the cleaningproduct in accordance with the invention shown in FIG. 1.

FIG. 5 shows an end view of a section of tubing used to construct theembodiment shown in FIG. 4.

FIG. 6 shows a side view of a section of tubing used to construct theembodiment shown in FIG. 4.

FIG. 7 shows a fourth embodiment of the cleaning product in accordancewith the invention shown in FIG. 4.

FIG. 8 shows a section view of the embodiment shown in FIG. 7.

FIG. 9 shows method of making the cleaning product shown in FIG. 3.

DETAILED DESCRIPTION

In describing the various embodiments of the instant invention,reference will be made herein to FIGS. 1-9 in which like numerals referto like features of the invention.

FIG. 1 depicts the external view of one embodiment of the invention (1).This embodiment resembles typical bath ruffles or mesh sponges on thesurface, but is formed around a foam core containing one or moreadditives.

FIG. 2 depicts a section view of one embodiment of the invention (1), acleaning product comprising a foam portion 10 containing one or moreadditives 70 for controlled release on contact with a water effluent. Insome embodiments, the foam portion is surrounded by a mesh spongeportion 20 comprised of extruded mesh tubing. In one embodiment, thefoam portion is preformed from an aqueous prepolymer mixture containingthe desired additives, such that the polymerization of the mixtureresults in a polymeric foam with the additives uniformly dispersed andincorporated directly into the matrix of the formed foam. This preformedfoam portion is then wrapped in one or more layers of extruded meshtubing 80, which is shaped to form a mesh sponge. In some embodiments,two or more types of mesh tubing, 90A and 90B, are used to form the meshsponge, to give a bath sponge having multiple colors or multiple surfacecharacteristics. In one embodiment, a mesh sponge is prepared, half froma fine, soft netting and half from a heavier, coarser netting to give amesh sponge having a softer side for general cleaning, and a coarserside for scrubbing or exfoliation. The resulting cleaning product isformed to the desired surface contour and texture for comfort andutility in use. In some embodiments, it is envisioned that at least aportion of the additives in the foam portion would be released by awetting effluent such as water, the additives then traveling from thefoam portion to the surface of the mesh sponge portion and from there tocontact a surface to be cleaned. In some embodiments, thecharacteristics of the foam portion are controlled such that the foamproduct will act to slow the release of the additives and provide formultiple use cycles before exhausting the supply of additives containedin the foam portion. In other embodiments, additional additives such assuperabsorbent polymers are added to the prepolymer mixture to form afoam matrix which will slow the release of the additives and provide formultiple use cycles. In one embodiment, the concentration of thesuperabsorbent polymers 60 added to the prepolymer mixture is fromapproximately 0.05% to 0.5% by weight superabsorbent polymer. In anotherembodiment, the concentration of the superabsorbent polymer is fromapproximately 0.1% to 0.2% by weight super absorbent polymer.

In other embodiments, additives are added to a preformed foam portion.In some embodiments, this is accomplished by compressing the foam, thenallowing it to expand in contact with the additive or with a solutioncontaining the additive. Expansion of the foam draws the additive or thesolution containing the additive a cell or cells of the foam.Evaporation of the solvent, if one is used, will then leave the additivedispersed in the foam matrix. In other embodiments, the foam portion isplaced in contact with the additive or a solution of the additive andsubjected to a vacuum, withdrawing the air from the cells of the foam tobe replaced by the additive or additive solution. Release of the vacuumwill then force additional additive or additive solution into the foam,and evaporation of the solvent, if any, will leave the additivedispersed inside the cells of the foam. Either of these embodimentswould facilitate the use of additives which would otherwise interferewith or be degraded by the polymerization reaction forming the foam.

In still other embodiments, some additives are added to the prepolymermixture before polymerization, and others added to the preformed foamportion after polymerization. The chemical nature of the additives andthe properties desired of the final product will guide the skilledpractitioner in selecting the appropriate method of introducing eachdesired additive to the foam portion of the invention.

FIG. 3 depicts an embodiment of the invention in which some parts ofstrands of extruded mesh tubing 30 which comprise the mesh portion 20 ofthe cleaning product run through foam portion 10. In one embodiment,this is accomplished mechanically by threading the mesh tubing throughchannels in a preformed foam portion. In another embodiment, this isaccomplished chemically by applying the prepolymer mixture to portionsof the extruded mesh tubing prior to polymerization, then allowing thepolymerization reaction to take place, trapping the strands of meshtubing as an integral part of the resulting foam matrix. In one exampleof this embodiment, strands of mesh tubing are threaded through a moldinto which a prepolymer mixture containing a selection of additives ispoured and allowed to polymerize. When the polymerization is complete,the mold is removed and the strands of mesh tubing outside the resultingfoam portion are arranged to form the mesh sponge portion.

FIGS. 4, 5, and 6 depict another embodiment of the invention in whichthe foam portion is in the form of a strip 40 running along the lengthof a portion of the mesh tubing 50. FIG. 4 shows a surface view of thecompleted embodiment, while FIGS. 5 and 6 show an end view and sideview, respectively, of a section of material used to form theembodiment. In one embodiment, this subassembly of mesh tubingincorporating the foam portion as a lengthwise strip is prepared bytreating a portion of the mesh tubing with a prepolymer mixturecontaining a selection of additives, and allowing the mixture topolymerize onto the mesh tubing, as shown in FIG. 5 (end view) and FIG.6 (side view). The subassembly is then arranged into the mesh spongeshown in FIG. 4. In another embodiment, one or more lengths of untreatedtubing are added to the subassembly which has been treated toincorporate the foam strip, and the whole is then formed into the meshsponge. In some embodiments, additional additives are added to the foamstrip subsequently by compression and soaking or by soaking undervacuum. Excess additive is washed from the mesh sponge portion, leavingthe additive in the foam strip.

FIGS. 7 and 8 depict an embodiment of the invention in which the meshsponge does not completely enclose the foam portion. In one embodimentthe exposed portion of the foam is attached to a handle, as shown inFIGS. 7 and 8. In another embodiment, the product is left unattached andthe exposed foam surface left available as an additional cleaningsurface. Other embodiments are envisioned wherein more or less of thefoam portion is left exposed by the mesh sponge portion.

FIG. 9 depicts a method of making a cleaning product consistent with anembodiment of the instant invention. A foam portion is provided 100which contains at least one additive and said foam portion is attachedto a mesh sponge portion. The mesh sponge portion is then shaped 110 sothat it generally encloses said foam portion. Next, at least an area ofthe mesh sponge portion is threaded 120 with at least an area of thefoam.

The foam portions for use in many embodiments of this invention includefoams comprising hydrophilic foam, hydrogel, hydrophobic foam,polyurethane, polyethylene, polyvinyl alcohol, polyvinylpyrrolidinone,and polyethylene oxide, and various combinations thereof. These foamsare typically polymers, made by combining components into a prepolymermixture and allowing the mixture to polymerize. In some embodiments,foaming agents are added to generate the cellular structure of theresulting polymeric foam. In other embodiments, gases are releasedduring the polymerization process, producing a polymeric foam. The foamsof some embodiments of the invention are formed from a polymerizedcombination of an aqueous mixture with a predetermined quantity ofhydrophilic urethane prepolymer. The introduction of one or moreadditives into the prepolymer mixture during or prior to polymerizationproduces a foam structure with the additives evenly dispersed throughoutthe foam matrix. Control of the polymerization process and the selectionof the additives allow the creation of a foam which will release somefraction of the total additive content during use, but retain asubstantial amount of additive for future use. In some embodiments,additives such as superabsorbent polymers are added to the prepolymermixture, allowing for further control of foam properties. Some foamssuitable for this application are described in U.S. Pat. No. 5,976,616to Celia et al., and U.S. Pat. No. 6,706,775 to Hermann et al.,incorporated by reference herein in their entirety. As discussed in U.S.Pat. No. 6,706,775, addition of small amounts of a superabsorbentpolymer to a hydrophilic polyurethane prepolymer mixture results in apolyurethane foam with higher water absorption than conventionalpolyurethane foams and reduced expression of additives from the foam ontreatment with water. Such foams control the release of additives,resulting in more useful cycles of wetting and drying before theadditives are exhausted.

In some embodiments of this invention, additives are included in theaqueous prepolymer mixture to modulate the properties of the foam formedby polymerization of the mixture. These additives include surfactants,superabsorbent polymers, foaming agents, copolymers, thickening agents,or various combinations of these materials to control the softness,texture, cell size, porosity, or water-absorbent properties of the foam.In some embodiments, certain of these additives are intended to beretained by the foam and not intended for release during use, and areincorporated into the structure of the foam in such a manner that theyare not released. In other embodiments, additives not intended forrelease during use are removed by evaporation or washing before theproduct is put to its intended use.

In some embodiments, additives such as odor absorbing compounds,preservatives, microbicides, and bactericides are added. In someembodiments, these additives are intended to preserve or extend thelifetime of the foam and are not intended for release during use. Inother embodiments, these additives are intended for release and deliveryto the surface being cleaned during the use of the product. In certainembodiments, such additives are incorporated into the structure of thefoam so they are not released during use. In some embodiments, thesecompounds are pre-encapsulated so that they are incorporated directlyinto the structure of the foam matrix. In one embodiment, granules ofactivated charcoal are encapsulated in polyurethane foam shells, whichthen react with the polymerizing mixture to fix the granules into thestructure of the foam. In another embodiment, additives are selectedwhich incorporate chemical functionality that cross-reacts withcomponents of the prepolymer mixture, incorporating the additiveschemically into the structure of the foam.

Still other additives suitable for incorporation into the foam portionof some embodiments of this invention include surfactants,superabsorbent polymers, soaps, detergents, waxes, polishes, drugs,cosmetics, biologicals, volatiles, odor absorbing and controllingcompositions, perfumes, oils, essential oils, vitamins, bactericides,microbicides, skin conditioning agents, moisturizers, and combinationsthereof. These additives are intended for release during use. In someembodiments, these additives are included in the aqueous prepolymermixture so that they are evenly distributed throughout the foam duringpolymerization. In other embodiments, the additives are added after thefoam is formed, either by soaking the foam in a solution of the additivein a suitable solvent, or by compressing the foam and allowing it toexpand in such a solution. Vacuum be applied during the soaking orcompression process to ensure maximum uptake of the additives. In stillother embodiments, some additives are incorporated during thepolymerization of the foam, and other additives are added to the formedpolymer foam after polymerization.

The function of the additives is determined by the purposes for whichthe product is intended. For embodiments intended for use as bathsponges, additives are selected which are expected to be safe for humanskin. Suitable formulations and ingredients are listed in a number ofgenerally available references available in the field, and a skilledpractitioner would be able to select formulations depending on theanticipated use of the product.

The mesh sponge portions of some embodiments of this invention areformed from polymeric net tubing. In some embodiments, a length of meshtubing is wound several times around a pair of spaced uprights, and theresulting coil of mesh tubing is fastened along at least one side, e.g.,by a cord or string wound perpendicularly to the coil and tied off. Thecoil is then released from the uprights and spread out to form a roughlyspherical bath sponge. Many types of polymer netting and methods ofconstructing a bath sponge are suitable for this invention, andnon-limiting examples of suitable bath sponge assembly can be found inU.S. Pat. Nos. 5,946,780 and 6,510,577 to Borcherds, et al., and U.S.Pat. No. 5,144,744 to Campagnoli, incorporated by reference herein intheir entirety.

In some embodiments, the foam portion and the mesh sponge portion of thecurrent invention are manufactured separately and attached by anattachment during assembly. In one embodiment the foam portion is sewnto the mesh sponge portion. In another embodiment, one or more cords areused to tie the foam portion to the mesh sponge portion. In otherembodiments, mechanical forms of attachment such as snaps, hook-and-loopfasteners, buttons, or hook-and-eye fasteners are affixed to theseparate mesh and sponge portions, and connected during assembly. Insome embodiments, products with such non-permanent attachment areprovided in kit form, or with a replacement foam portion and meshportion separately available. Adhesives, glues, solvents, or heat orother forms of energy are used to form a bond between the foam portionand the mesh sponge portion in other embodiments. These examples areintended to be illustrative only, and non-limiting.

In other embodiments, the attachment of the foam portion and the meshportion is designed as part of the assembly process of one or the otherportion. In one embodiment, the foam portion is attached to the cordwhich is used to bind the mesh sponge coil prior to its release from theuprights and formation of the mesh sponge. In another embodiment,portions of a completed mesh sponge are threaded through the prepolymermixture used to form the foam portion, and incorporated into the foammatrix during the polymerization process. In yet another embodiment, alength of mesh tubing is partially dipped into a prepolymer mixturealong its entire length. Subsequent polymerization yields a segment ofmesh tubing incorporating the foam portion as a strip along its entirelength. This length of tubing is then wound about a pair of uprights,tied off, and formed into the cleaning product of the current invention.In still another embodiment, the tubing intended to form the mesh spongeportion is threaded through holes or channels in a preformed polymerfoam, which then holds the mesh sponge in place during subsequentassembly. Other examples could be readily visualized by a person skilledin the art and such modifications are intended to be included within thescope of this invention.

In other embodiments, the mesh sponge portion is formed around apreformed foam portion, generally, partially or substantially enclosingthe foam portion such that further attachment is not necessary.

In some embodiments, two or more types of netting tube are used to formthe mesh sponge, to give a bath sponge having multiple colors ormultiple surface characteristics. In one embodiment, a mesh sponge isprepared, half from a fine, soft netting and half from a heavier,coarser netting to give a mesh sponge having a softer side for generalcleaning, and a coarser side for scrubbing or exfoliation.

In some embodiments, a surface of the foam portion is attached to asurface of the mesh sponge portion, to give a cleaning product havingsome of the surface area of the foam portion exposed for use as acleaning surface. In other embodiments, the foam portion is totallyenclosed by the mesh sponge portion.

One or more handles can be affixed to the cleaning products of thisinvention to extend the reach of the user or to adapt the cleaningproduct for other uses. In some embodiments, these handles are rigid orsemi-rigid structures to which the cleaning product is attached,allowing a user to apply the cleaning product and the entrappedadditives to areas which would otherwise be awkward or difficult toreach. In other embodiments, these handles are more flexible, in theform of straps, belts, or cords.

While the present invention has been particularly described, it isevident that many alternatives, modifications and variations will beapparent to those skilled in the art in light of the foregoingdescription. It is therefore contemplated that the appended claims willembrace any such alternatives, modifications, and variations as fallingwithin the true scope and spirit of the present invention.

What is claimed is:
 1. A cleaning product comprising a foam portioncontaining at least one additive, said foam portion attached to a meshsponge portion.
 2. The cleaning product of claim 1 wherein said foamportion is generally enclosed by said mesh sponge portion.
 3. Thecleaning product of claim 1 wherein the foam portion is selected fromthe group consisting of: hydrogels, hydrophilic foams, hydrophobicfoams, polyurethane, polyethylene, polyvinyl alcohol,polyvinylpyrrolidinone, cellulose, and polyethylene oxide andcombinations thereof.
 4. The cleaning product of claim 1 wherein the atleast one additive is selected from the group consisting of: soaps,detergents, waxes, polishes, drugs, cosmetics, biologicals, volatiles,odor absorbing and controlling compositions, perfumes, oils, essentialoils, vitamins, bactericides, microbicides, skin conditioning agents,moisturizers, and combinations thereof.
 5. The cleaning product of claim1 wherein the at least one additive is generally dispersed throughoutthe matrix of the foam portion.
 6. The cleaning product of claim 1wherein the foam portion also comprises at least one superabsorbentpolymer.
 7. The cleaning product of claim 1 wherein the mesh spongeportion comprises at least one layer of netting arranged in the form ofa bath ruffle.
 8. The cleaning product of claim 1 wherein the meshsponge portion comprises a netting of at least two different materialsor textures.
 9. The cleaning product of claim 1 wherein said foamportion contains at least one additive selected from the groupconsisting of: soaps, detergents, waxes, polishes, drugs, cosmetics,biologicals, volatiles, odor absorbing and controlling compositions,perfumes, oils, essential oils, vitamins, bactericides, microbicides,skin conditioning agents, moisturizers, plant extracts, and combinationsthereof; and wherein the mesh sponge portion comprises at least onelayer of a netting arranged in the form of a bath ruffle generallyenclosing said foam portion.
 10. A method of manufacturing a cleaningproduct comprising the steps of: providing a foam portion containing atleast one additive; and attaching said foam portion to a mesh spongeportion.
 11. The method of claim 10, further comprising the step ofshaping said mesh sponge portion so that it generally encloses said foamportion.
 12. The method of claim 10, further comprising with step ofthreading at least an area of the mesh sponge portion with at least anarea of the foam portion.
 13. A cleaning product comprising a meshsponge portion and a foam portion comprising at least one additivewherein a part of the mesh sponge portion is contained within at least apart of the foam portion.
 14. The cleaning product of claim 13 whereinthe foam portion is selected from the group consisting of: hydrogels,hydrophilic foams, hydrophobic foams, polyurethane, polyethylene,polyvinyl alcohol, polyvinylpyrrolidinone, and polyethylene oxide andcombinations thereof.
 15. The cleaning product of claim 13 wherein theat least one additive is selected from the group consisting of: soaps,detergents, waxes, polishes, drugs, cosmetics, biologicals volatiles,odor absorbing and controlling compositions, perfumes, oils, essentialoils, vitamins, bactericides, microbicides, skin conditioning agents,moisturizers, and combinations thereof.
 16. The cleaning product ofclaim 13 wherein the at least one additive is generally disperseduniformly throughout the foam portion.
 17. The cleaning product of claim13 wherein the foam portion also comprises at least one superabsorbentpolymer.
 18. The cleaning product of claim 13 wherein the mesh spongeportion is composed of at least one layer of netting arranged in theform of a bath ruffle.
 19. The cleaning product of claim 13 wherein themesh sponge portion comprises a netting of at least two differentmaterials or textures.
 20. The cleaning product of claim 13, wherein atleast an area of said mesh sponge portion is threaded through at leastan area of said foam portion.